Electric and combustion forklift maintenance guide

Did you know that some operations and logistics managers value the cost of downtime for electric and combustion forklifts at thousands of euros per minute? Yes, per minute and not per hour as many think.

Precisely, a system for managing industrial preventive maintenance, The use of a lift truck, or the proper maintenance of these lift trucks, can help prevent costly downtime.

If you are in charge of forklift maintenance or are responsible for downtime on the job, here's an overview of how you can help. easy guide to maintenance of electric and combustion forklifts.

Step one: safety is a priority in the maintenance of electric and combustion forklifts.

As a cornerstone, we have to consider workplace safety during the maintenance of electric and combustion forklifts. Safety tasks are closely related to best practices and high standards during the maintenance process.

The Occupational Safety and Health Administration (OSHA) has established guidelines and regulations regarding occupational safety, more specifically in the maintenance of electric and combustion forklifts, pointing out several measures and demonstrating in recent studies that there is a 20-40% reduction in costs after implementing safety plans for this type of vehicle. 

General Forklift Safety: Daily Checklists

As a general rule, forklift trucks should be inspected by their operators on a daily basis prior to use by simple checks both when the load vehicle is switched off and when it is switched on.

While we realise that these checks may seem obvious to operators, the checks, which typically take approximately three minutes at most, result in a safer operating environment and undoubtedly lower maintenance costs for electric and combustion forklifts, people and workplaces.

Forklift Off Checklist

• Check fluid levels (fuel, water, hydraulics): low fluid levels can cause machine malfunctions, such as forks or blades not lifting properly or brakes not working, which can cause a variety of accidents.
• If you find very visible damage, notify those in charge: reports visible damage that in the end this information may end up saving major repairs in the future and unnecessary costs in the maintenance of electric and combustion forklifts.
• Check the condition and pressure of the tyres: damaged tyres or wheels with low air pressure will cause the forklift truck not to operate as safely or effectively as possible.
• Lifting forks or blades must be in good condition: poorly maintained fork operation can cause serious damage to the machine and cause loads to slip or, worse, injure operators and/or co-workers. 
• Inspection stickers must be in the correct place and be legible: This is an OSHA requirement and ensures that a forklift can be quickly identified.
• Make sure the cabin is clean and free of debris: A dirty and poorly maintained cab can cause accidents and prevent the desired transport from being carried out. 
• Safety devices must be in good working order: People and their well-being come first. Safety equipment is there for a reason - keep it in good condition so you're safe!

Maintenance of electric forklifts 

1. Make sure there are no broken or frayed wires.
2. Check battery restrictions.
3. Battery electrolytes must be at the proper levels; batteries are usually lead-acid or nickel-iron and are recharged by connecting the forklift to a stationary station or with an “on-board” charger inside the forklift. Because batteries contain corrosive chemicals that can cause burns to the eyes and skin, wear personal protective equipment to prevent contact and splashing, and such equipment should include: Rubber gloves, Safety goggles and face shields, An apron, Steel-toed boots to protect feet against crushing hazards. Electrolytes allow energy to flow between the vehicle and the battery. If they are not at the right levels, the performance of the charges will be affected or simply will not work.
4. The bonnet lock must be secure so that it cannot be opened and cause accidents. You must also keep the bonnet secure to prevent debris from entering and damaging the engine as well as the forklift chassis.

Maintenance of internal combustion forklifts

1. Check the engine oil and coolant. The engine is one of the most expensive parts of a forklift and keeping the amount of fluid at the correct levels keeps it healthy.
2. Check the brake fluid and make sure it is at the correct level.
3. Engine belts and hoses must be in good condition.
4. The radiator and air filter must also be in good condition.
5. The bonnet lock must be secure.

LPG forklift maintenance

1. Make sure that the gas tank is correctly mounted.
2. Check the tank for damage and/or leaks. If you find white frost, strong odour and/or hear a hissing sound, there could be a leak. 
3. The exhaust valve should be pointing upwards, ensuring that the tank is correctly aligned with the forklift truck to avoid accidents and ensure that most of the gas is consumed. 
4. Hoses and belts must be in good condition.

Checklist while operating a forklift truck

• Make sure the steering, throttle and brakes are working properly.
• Check that the gears operate correctly both front and rear.
• Make sure the lift is working and has the proper tilt.
• Check that the horn, lights and back-up alarm are working.

For a more complete guide, please see how to reduce forklift operating costs with condition monitoring and even access to the details of an adequate maintenance plan for electric and combustion forklift trucks, subscribe to the Technology for Industry newsletter.